Deck installation track and method

ABSTRACT

A device, system and method for installing decking are described. A track for decking has a base element, a first snap-fit element coupled to the base element, and a second snap-fit element coupled to the base element, the second snap-fit element opposing the first snap-fit element. At least one of the first snap-fit element or the second snap-fit element has an inward protrusion to engage a recess in a side of a decking board, whereby the first and second snap-fit elements are retain the decking board.

PRIORITY

The present application is a Continuation of U.S. patent applicationSer. No. 15/221,463 entitled “DECK INSTALLATION TRACK AND METHOD,” filedJul. 27, 2016, which claims priority from, and is a Continuation of,U.S. patent application Ser. No. 14/480,172 entitled “DECK INSTALLATIONTRACK AND METHOD,” FILED Sep. 8, 2014, which claims priority from, andis a continuation-in-part of, U.S. patent application Ser. No.29/411,646, entitled “DECK INSTALLATION TRACK,” filed on Jan. 24, 2012,all of which are applications by Applicant Mark A. Claudin, and areincorporated herein by reference.

COPYRIGHT

A portion of the disclosure of this patent document contains materialthat is subject to copyright protection. The copyright owner has noobjection to the facsimile reproduction by anyone of the patentdisclosure, as it appears in the Patent and Trademark Office patentfiles or records, but otherwise reserves all copyright rightswhatsoever.

FIELD OF THE INVENTION

The present invention relates to construction. In particular, but not byway of limitation, the present invention relates to systems and methodsfor installing decking.

BACKGROUND OF THE INVENTION

Decking is a popular addition to many homes and businesses.Historically, decking has been installed by building a support beamfoundation system topped by a joist system, and then attaching deckingboards on top of the joist system. The decking boards are often made ofcomposite materials. To attach the deck boards to the joist system, themost direct approach has been to nail or screw directly through from thetop of the deck board through to the joist, as shown in FIG. 38C. Then,to conceal the screw and improve the aesthetic appeal and life of thedeck, a plug may be used. An angled attachment, as shown in FIG. 38B hasalso been proposed. To provide for appropriate spacing between the deckboards, gapping tools, such as that shown in FIG. 38C may be installedand attached to the joist as well.

In other methods, a concealed gapping and fastening tool, such as thatshown in FIG. 38A, has been developed. This concealed gapping andfastening tool is (generally forcibly) inserted into a side of the deckboard, and then screwed into the joist using a 45 degree angle.

Although each of the above methods are functional, they are laborintensive and require a high degree of skill on the part of the deckinstaller, requiring, for example fairly precise locating skills on thepart of the installer; that is, the installer must guess where the joistis located when installing according to FIG. 38C. In the alternative,the installer must be skilled enough to appropriately angle and attachthe screw, as shown in FIGS. 38A-38B and/or use a costly aligning toolto achieve the appropriate angle. Finally, each of the devices in FIGS.38A-38C are relatively small in size, leading to a high loss of materialand/or material hunting on the part of the installer when the componentsfall to the ground below the deck. None of the previous approaches allowfor a replacement of old decking boards without removing and replacingthe attachment components.

Accordingly, a system and method are needed to address the shortfalls ofpresent technology and to provide other new and innovative features.

SUMMARY OF THE INVENTION

An exemplary track for decking has a base element, a first snap-fitelement coupled to the base element, and a second snap-fit elementcoupled to the base element, the second snap-fit element opposing thefirst snap-fit element. At least one of the first snap-fit element orthe second snap-fit element has an inward protrusion configured toengage a recess in a side of a decking board, whereby the first andsecond snap-fit elements retain the decking board.

An exemplary track for decking has a base element, a first resilientmember coupled to the base element, and a second resilient membercoupled to the base element, the second resilient member opposing thefirst resilient member. At least one of the first resilient member orthe second resilient member has an inward protrusion to engage a recessin a side of a decking board, whereby the first and second resilientmembers retain the decking board.

An exemplary method of installing a decking board includes providing atrack having a base element, a first snap-fit element coupled to thebase element, and a second snap-fit element coupled to the base element,the second snap-fit element opposing the first snap-fit element, whereinat least one of the first snap-fit element or the second snap-fitelement has an inward protrusion configured to engage a recess in a sideof a decking board. The exemplary method includes causing the first andsecond snap-fit elements to resiliently engage the recess, whereby thefirst and second snap-fit elements retain the decking board.

BRIEF DESCRIPTION OF THE DRAWINGS

Various objects and advantages and a more complete understanding of thepresent invention are apparent and more readily appreciated by referenceto the following detailed description and to the appended claims whentaken in conjunction with the accompanying drawings wherein:

FIG. 1 is a perspective view of a track according to one embodiment;

FIG. 2 is a top view of the track in FIG. 1;

FIG. 3 is a bottom view of the track in FIG. 1;

FIG. 4 is a front view of the track in FIG. 1 showing a relationship toa decking board;

FIG. 5 is a side view of the track in FIG. 1;

FIG. 6 is a perspective view of a track according to another embodiment;

FIG. 7 is a top view of the track in FIG. 6;

FIG. 8 is a bottom view of the track in FIG. 6;

FIG. 9 is a front view of the track in FIG. 6 showing a relationship toa decking board;

FIG. 10 is a right side view of the track in FIG. 6;

FIG. 11 is a left side view of the track in FIG. 6;

FIG. 12 is a perspective view of a track according to anotherembodiment;

FIG. 13 is a top view of the track in FIG. 12;

FIG. 14 is a bottom view of the track in FIG. 12;

FIG. 15 is a front view of the track in FIG. 12;

FIG. 16 is a right side view of the track in FIG. 12;

FIG. 17 is a left side view of the track in FIG. 12;

FIG. 18 is a perspective view of a track according to anotherembodiment;

FIG. 19 is a top view of the track in FIG. 18;

FIG. 20 is a bottom view of the track in FIG. 18;

FIG. 21 is a front view of the track in FIG. 18;

FIG. 22 is a side view of the track in FIG. 18;

FIG. 23 is a perspective view of a track according to anotherembodiment;

FIG. 24 is a top view of the track in FIG. 23;

FIG. 25 is a bottom view of the track in FIG. 23;

FIG. 26 is a front view of the track in FIG. 23;

FIG. 27 is a side view of the track in FIG. 23;

FIG. 28 is a perspective view of a track according to anotherembodiment;

FIG. 29 is a top view of the track in FIG. 28;

FIG. 30 is a bottom view of the track in FIG. 28;

FIGS. 31 and 31A are front views of the track in FIG. 28;

FIG. 32 is a side view of the track in FIG. 28;

FIG. 33 is a top view of a track according to another embodiment;

FIG. 34 is a front view of the track in FIG. 33;

FIG. 35 is a side view of the track in FIG. 33;

FIG. 36 is a perspective view of a track according to anotherembodiment;

FIG. 37 is a flow diagram of a method according to an embodiment; and

FIGS. 38A-38C are front views illustrating the relationship betweenvarious prior art tracks and decking boards.

DETAILED DESCRIPTION

Referring now to the drawings, where like or similar elements aredesignated with identical reference numerals throughout the severalviews, and referring in particular to FIGS. 1-5, shown is a deckinstallation track, or track 100, for short. The track 100 comprises abase element 102 having at least one attachment element 104, a firstsnap-fit element 106 attached to a first end portion 108 of the baseelement 102, and a second snap-fit element 110 attached to a second endportion 112 of the base element 102 create a retaining portion orretaining feature of the track 100. The track 100 may be manufactured ofany material suitable for the expected function of installing andmaintaining decking boards, such as the decking board 114 shown in FIG.4, including, without limitation, steel, iron, composites, plastics,aluminum, and combinations thereof, treated to withstand typicaltemperature and other various weather fluctuations.

As shown in FIGS. 1-5, the base element 102 includes at least oneattachment element 104. The attachment element 104 may be one or morethrough-holes as shown, to allow a screw, nail, or other attachmentdevice 116 to allow the track 100 to be screwed or nailed onto a joistof a decking base. Placement of the attachment element 104 may be suchthat, after a decking board 114 is installed, the decking board 114 mayalso be removed by pulling up without bending or otherwise destroyingthe base element 102. More specifically, as shown more clearly in FIG.12, a distance D between two attachment elements 104 may be greater thanbetween an attachment element 104 and an end portion 108, 112 to improvethe removability of a track 100 without damaging the track 100.

Although a through-hole is shown, it should be understood by thoseskilled in the art that the attachment element 104 may comprise othermeans for attachment to a joist, such as, without limitation, a clipextending around the base element 102 and joist, and a slot for allowinga nail or screw to attach the base element 102 to the joist. It shouldalso be understood that, even where a through-hole is used, it is notnecessarily limited to a centered placement on the base element 102.

Continuing with FIGS. 1-5, the snap-fit elements 106, 110 are nowdiscussed. As seen, the snap-fit elements 106, 110 are attached to thebase element 102, and extend upwards to form a space between thesnap-fit elements 106, 110 for receiving a decking board 114therebetween. The snap-fit elements 106, 110 may each include an inwardprotrusion 106 a, 110 a configured to protrude into a recess 114 a inthe decking board 114, to provide a snap-fit between the track 100 andthe decking board 114. The protrusions 106 a, 110 a may include a bend,as shown, a raised welded surface, or any other appropriate protrusion106 a, 110 a suitable for retaining a decking board 114 in between thespacing formed by the first and second snap-fit elements 106, 110.

The first and/or second snap fit elements 106, 110 may be formedcontinuously with the base element 104 at a bend 112, as shown in FIGS.1-5, for they may be attached by other means, such as gluing, screwing,bonding, casting, or welding. As one example, FIGS. 6-11, illustrate atrack 200 having snap-fit elements welded on the base element 104 atweld seam 212.

Turning now to FIGS. 4 and 34, an elevating element 118, 718 is nowdiscussed. As seen, after installation of the track 100 and the deckingboard 114, the decking board 114 may be maintained slightly above theattachment element 104, so as to protect the life of the decking board114 by ensuring water is not pulled about the underside of the deckingboard 114. In FIG. 4 the elevating element 118 is the head of a screw ornail. In FIG. 34, the elevating element 718 is a bend in the baseelement 702. It is noted that the elevating element 718 shown in FIG. 34provides a secondary advantage in that the bend provides a strengtheningeffect to the base element 702.

Returning now to FIGS. 1-5, it should be understood that the spacingbetween the first and the second snap-fit elements 106, 110 may beconfigured to have a distance D to fit a variety of standard ornon-standard decking boards 114. Likewise, the snap-fit elements 106,110 may be configured to fit a variety of standard or non-standarddecking boards 114.

It should also be understood that the first and second end portions 108,112 of the track 100 may be repeated, as shown in FIGS. 1-32, such aswith a continuous track having multiple sub-tracks 100, or the first andsecond end portions 708, 712 may end into bends to form the snap-fitelements, as shown in FIGS. 33-35. It should also be understood that thefirst snap-fit element 106 and the second snap-fit element 110 mayrepeat in a pattern forming a sub-track having a plurality of centralsnap-fit elements to allow for the installation of a plurality ofdecking boards 114, as most clearly shown in FIGS. 1, 4, and 31A.

Further, although shown in FIGS. 1-22 as having snap-fit elements 106,110 that do not extend across the entire width W of the base element102, it should be understood that, as shown in FIGS. 23-36, illustratingalternative embodiments of the track 500, 600, 700, 800, the snap-fitelements 806, 810 may extend across the entire width W of the baseelement 802.

Turning now to FIGS. 6-11, another embodiment of the track 200 is shown.As previously discussed, the snap-fit elements 206, 210 may be weldedonto the base element 202 using a welded joint 212. It is also shown inFIGS. 6-11 that the first and the second snap-fit elements 206, 210 maybe unitary with one another, forming protrusions on opposing sides, soas to enable a repeating pattern to be formed across the length of thebase element 202. This repeating pattern may be used to install aplurality of decking boards 114 next to each other while maintaining adesired spacing between each of the decking boards 114.

The unitary snap-fit elements 206, 210 may have an open top 207 to allowfor independent expansion/contraction of the associated decking board114, or, as in the track 300 shown in FIGS. 12-17, the unitary snap-fitelements 306, 310 may have a closed top 307 to strengthen a retaininghold on the associated decking board 114.

Turning now to the track 400 shown in FIGS. 18-22, the snap-fit elements406, 410 may be configured to fit a variety of decking boards usingprotrusions 406 a, 410 a that include sharp corners, as shown. The sharpcorners may also provide a strong and/or permanent retaining force onthe decking board 114. That is, the sharp corners may in someembodiments provide for a deck and track 400 that is not removable.

Turning now to the track 500 shown in FIGS. 23-27, the first snap-fitelement 506 of a first sub-track may be attached to the second snap-fitelement 510 of a second sub-track to form a track 500 having a repeatedpattern. The first snap-fit element 506 and the second snap-fit element510 may be formed using a continuous piece of material, as shown inFIGS. 23-32. Similarly, the first snap-fit element 506 and/or the secondsnap-fit element 510 may be formed along with the base element 502 froma continuous piece of material. As an alternative, the snap-fit elementsmay be independently formed and later welded, perhaps using spot welds706 b, 810 b between an outer wall of a first snap-fit element and anouter wall of a second snap-fit element as shown in FIGS. 35-36.

As seen in FIGS. 28-32, the snap-fit elements 606, 610 of the track 600may include inwardly curved portions while also being formedcontinuously with the base element 602 to form a repeating pattern. InFIG. 31A, the relationship between the track 600 and a joist 130 isshown. As seen, the track 600 is installed lengthwise along the joist130 using a plurality of attachment devices 116 or screws, therebycovering a substantial portion of the top of the joist 130 andprotecting the top of the joist 130 from weathering. After the track 600is installed, a plurality of decking boards 114 are snapped into thespaces between the snap-fit elements 606, 610, as shown.

Turning now to FIGS. 33-35, another embodiment is now discussed. In thetrack 700 shown in FIGS. 33-35, one or more of the end portions 708, 712of the track may have two snap-fit elements attached. That is, the track700 may have a first and a second snap-fit element 706, 710 configuredto retain an end portion of a first decking board 114, as well as athird snap-fit element 720 and a fourth snap-fit element 722 configuredto retain an end portion of a second decking board 115, as shown in FIG.33. It should be understood that, although the first, second, third, andfourth snap-fit elements 706, 710, 720, 722 are configured to retain twodecking boards 114, 115, the four snap-fit elements may retain just onedecking board 114 at a mid-portion of the decking board 114.

As previously described, the track 700 may include an elevating element718 to maintain the decking board 114, 115 elevated above the baseelement 702. The elevating element 718 may include a bend in the baseelement 702, the head of a screw or nail 118, or any other raisedportion, such as, without limitation, a raised welded spot or seam. Thewelded seam 212, 312 seen in FIGS. 6-17 may be used to elevate thedecking board along with the previously-described role of attaching thesnap-fit elements, as just one example. In the alternative, a raisedwelded spot 818 or ridge may be applied anywhere along the base element802, as shown in FIG. 36.

Turning now to FIG. 37, a method 900 of installing decking is nowdescribed. The method 900 includes aligning a deck installation track902, attaching the track 904, and snapping a decking board 906 into aretaining portion of the track.

Aligning 902 includes aligning a track according to at least one of thetracks 100, 200, 300, 400, 500, 600, 700, 800 previously described inthis disclosure such that the track runs along a joist 130, as shown inFIG. 31A or FIG. 36, for example. That is, an elongated portion of abase element in the track is aligned with an elongated portion of thejoist. In some embodiments, such as where the track comprises a repeatedpattern of snap-fit elements, the method 900 may include aligning 902such that the base element protects a substantial portion of the top ofthe joist from weather. More specifically, the track may extend along asignificant portion of the joist, and aligning 902 the track over thejoist may provide weather protection to the joist.

Attaching 904 includes using one or more attachment devices 116 andattachment elements 104, which may be similar to the attachment devicesand elements 116, 104 previously described, to temporarily orsemi-permanently affix the track to the joist. In some embodiments,attaching 904 may include using a screw to attach the track, and settingthe screw into the joist at approximately a ninety degree angle relativeto a top of the joist, while maintaining a direct line of site betweenthe installer and the attachment element, such as attachment element104, while attaching the track.

Snapping 906 includes using a decking board 114 to apply enough downwardpressure to cause the snap-fit elements of the track to deform,providing enough space between the snap-fit elements for the deckingboard to move down into the space between the snap-fit elements.Snapping 906 also includes releasing the decking board 114, and allowinginward protrusions of the snap-fit elements to partially fill a recessin a side of the decking board 114, as shown in FIG. 4, and permanentlyor semi-permanently retaining the decking board in position. In someembodiments, the method 900 may include snapping an end portion of thedecking board into a spacing between a first snap-fit element and asecond snap-fit element, or the method 900 may include snapping acentral portion of the decking board into a spacing between the firstsnap-fit element and the second snap-fit element. In some embodiments,snapping may include overcoming a resistance of a material having ahardened material, such as hardened steel, to press a decking board intoposition. In some embodiments, snapping may include overcoming aresistance of a material having a Rockwell hardness of greater than 64to press a decking board into position.

In some embodiments, the method 900 may include maintaining the deckingboard elevated relative to the attachment element using an elevatingelement.

The method 900 may include snapping a plurality of decking boards intoposition after attaching the track.

The method 900 may include using a plurality of snap-fit elements tomaintain a consistent spacing between each of a plurality of deckingboards.

The method 900 may include attaching a plurality of tracks, eachcomprising a plurality of snap-fit elements and a plurality ofattachment elements.

The method 900 may include snapping an end portion of a first deckingboard into a spacing between the first snap-fit element and the secondsnap-fit element; and snapping an end portion of a second decking boardinto a spacing between a third snap-fit element at the first end portionof the base element and a fourth snap-fit element at the second endportion of the base element.

The method 900 may include causing the first decking board to fluctuatein size longitudinally and transversely; causing the second deckingboard to fluctuate in size longitudinally and transversely andindependent of the first decking board; maintaining a snap-fit to thefirst decking board; and maintaining a snap-fit to the second deckingboard independent of the first decking board.

In conclusion, embodiments of the present invention provide, among otherthings, a device and method for installing decking. Those skilled in theart can readily recognize that numerous variations and substitutions maybe made in the invention, its use and its configuration to achievesubstantially the same results as achieved by the embodiments describedherein. Likewise, a variety of combinations of the elements shown in thenumerous embodiments may be made. Accordingly, there is no intention tolimit the invention to the disclosed exemplary forms. Many variations,modifications and alternative constructions fall within the scope andspirit of the disclosed invention as expressed in the claims.

What is claimed is:
 1. A track for decking; comprising: a base element;a first snap-fit element coupled to the base element; and a secondsnap-fit element coupled to the base element, the second snap-fitelement opposing the first snap-fit element; wherein at least one of thefirst snap-fit element or the second snap-fit element comprises aninward protrusion configured to engage a recess in a side of a deckingboard, whereby the first and second snap-fit elements are configured toretain the decking board.
 2. The track of claim 1, wherein: the firstsnap-fit element and the second snap-fit element are configured toretain a first end portion of a first decking board; and the firstsnap-fit element and the second snap-fit element are configured toretain a first end portion of a second decking board.
 3. The track ofclaim 1, comprising: a third snap-fit element coupled to the first endportion of the base element; and a fourth snap-fit element coupled tothe second end portion of the base element; wherein: the first snap-fitelement and the second snap-fit element are configured to retain a firstend portion of a first decking board; and the third snap-fit element andthe fourth snap-fit element are configured to retain a first end portionof a second decking board.
 4. The track of claim 1, further comprising:at least one attachment element for attaching the track to a joist. 5.The track of claim 1, wherein: at least a portion of the first andsecond snap-fit elements comprises a hardened steel.
 6. The track ofclaim 1, wherein: at least one of the first snap-fit element and thesecond snap-fit element is configured to be displaced while a user snapsthe decking board into a retained position.
 7. The track of claim 1,wherein: the base element is configured to protect a substantial portionof the top of the joist from weather.
 8. The track of claim 1,comprising: an elevating element configured to maintain the deckingboard elevated relative to the attachment element after the deckingboard is snapped into a retained position.
 9. The track of claim 1,comprising: a plurality of central snap-fit elements attached to thebase element between the first and second end portions of the baseelement; wherein the first snap-fit element, the second snap-fitelement, and the plurality of central snap-fit elements are configuredto maintain a consistent spacing between each of a plurality of deckingboards.
 10. The track of claim 1, wherein: the at least one of the firstor second snap-fit elements has a first flange extending upwardlyrelative to the base, a second flange extending inwardly from the firstflange, and a third flange extending outwardly from the second flange,the second flange and the third flange forming the inward protrusion.11. The track of claim 10, wherein: the second flange is configured toabut a lower portion of the recess and the third flange is configured toabut an upper portion of the recess to removably retain the deckingboard.
 12. The track of claim 1, further comprising: a compositematerial, a plastic, or a combination thereof.
 13. The track of claim 1,wherein: at least one of the first snap-fit element or the secondsnap-fit element is unitary with the base element.
 14. A track fordecking; comprising: a base element; a first resilient member coupled tothe base element; and a second resilient member coupled to the baseelement, the second resilient member opposing the first resilientmember; wherein at least one of the first resilient member or the secondresilient member comprises an inward protrusion configured to engage arecess in a side of a decking board, whereby the first and secondresilient members are configured to retain the decking board.
 15. Thetrack of claim 14, wherein: at least one of the resilient memberscomprises a plastic, a composite, or a combination thereof.
 16. A methodof installing a decking board, the method comprising: providing a trackhaving a base element, a first snap-fit element coupled to the baseelement, and a second snap-fit element coupled to the base element, thesecond snap-fit element opposing the first snap-fit element, wherein atleast one of the first snap-fit element or the second snap-fit elementcomprises an inward protrusion configured to engage a recess in a sideof a decking board; causing the first and second snap-fit elements toresiliently engage the recess, whereby the first and second snap-fitelements retain the decking board.
 17. The method of claim 16, furthercomprising: pressing the decking board downward towards the baseelement;
 18. The method of claim 16, further comprising: displacing atleast one of the first snap-fit element and the second snap-fit element;and pressing or snapping the decking board into a retained position. 19.The method of claim 16, wherein: the providing a track comprisesproviding an elevating element configured to maintain the decking boardelevated relative a joist after the decking board is installed.
 20. Themethod of claim 16, wherein: the providing a track comprises providing aplurality of central snap-fit elements attached to the base elementbetween the first and second snap-fit elements, wherein the firstsnap-fit element, the second snap-fit element, and the plurality ofcentral snap-fit elements are configured to maintain a consistentspacing between each of a plurality of decking boards; and the methodfurther comprises attaching a plurality of decking boards to the trackby pressing the plurality of decking boards against the track.